Tackle Dairy Challenges with the Right Equipment

In addition, pneumatics technology is well-positioned to utilize Industrial Internet of Things (IIoT) capabilities. New IIoT edge devices can collect data from the pneumatic system to identify leaks, monitor energy usage and air consumption, and calculate the life expectancy or mission time of a pneumatic component. For example, by using appropriate data from an IIoT gateway device, maintenance technicians can predict that a shock absorber at the end of an actuator is deteriorating just by sensing an increase in its stroke speed, even if only by a few milliseconds. By knowing which equipment needs maintenance before it actually fails, plant engineers can avoid unplanned machine downtime and replace defective components with shorter and fewer machine stoppages.

Performance

Pneumatics equipment can handle high-speed production or high-speed motion sequences, using valves engineered for high actuation rates. Pneumatically operated pilot valves can be used throughout the facility to actuate a variety of critical on/off process valves and packaging equipment. They’re used extensively in packaging lines where weight and high cycling are critical. They perform in short to long strokes in a variety of operating conditions from high temperatures and high pressures for aggressive washdowns. Plus, they have high shock absorbance.

Cost Efficiency

Pneumatics technology generally has a lower initial cost than electronics on a component versus component basis, and is extremely cost-effective in operation, routinely saving operational expense because of its energy efficiency, reliability, and low maintenance costs. While electric devices may offer more control, that added capability may not be as relevant in food and dairy processing as it is in other industries. In addition, pneumatic technology is more washdown -friendly than electrical devices, which need a temperature-controlled environment to avoid overloaded circuits.

Compressed air is usually available throughout a dairy plant, so connecting more devices when needed for a new application usually results in little incremental cost. In fact, the more pneumatics connected to a compressor and the closer the total demand is to the capacity of the compressor, the more efficient pneumatics becomes. Conversely, a smaller number of pneumatic components using a smaller portion of a compressor’s capacity would be less efficient in operation. That’s why it’s best to evaluate costs on a case-by-case basis.

Worker Safety

Pneumatics can help address plant safety issues in several ways using a proven technology (compressed air). As a result, dairy producers hoping to comply with ISO and other regulatory standards have a wide range of traditional pneumatics products to choose from.

For example, Emerson is advancing an integrated, scalable zoned safety approach, allowing up to three safety zones to be isolated on a machine from a single pneumatic assembly. With zoned safety, the valve manifold can be configured to shut down pilot air and power only to the control equipment that will come in contact with the operator. The rest of the machine can remain in operation. Zoned safety helps design engineers satisfy Machinery Directive 2006/42/EC and comply with ISO 13849-1 and ISO 13849-2. It reduces the number of safety system components by up to 35 percent, requires fewer connections, and saves valuable real estate within the machine and manifold.

Versatility

Compressed air is normally available throughout the typical dairy processing facility, so dairy processors can deploy pneumatics almost anywhere in the plant. And, at a deeper level, pneumatic devices prove their versatility by communicating across a wide range of industry protocols, like Ethernet-based protocols, Open System Interconnection (OSI), and IO-Link, and even Process Field Bus (PROFIBUS) and DeviceNet. As a result, it’s easier for dairy processors to use pneumatic devices that comply with national and international standards, anywhere in the world.

This high level of flexibility has allowed the dairy industry to deploy pneumatics in a widespread fashion. Equipment designers are learning to specify pneumatics quickly and easily, helping dairy machine OEMs meet end-user requirements for machines that are faster, more efficient, or consume less energy or air. Dairy processors are deploying pneumatics throughout their plants, reducing ramp up and training time required when they introduce new equipment. Dairy plant workers are developing a high level of familiarity, learning how to operate and maintain pneumatics equipment and controls.

Plant Engineering Advice for Implementing Pneumatics

There are several key best practices to follow when implementing pneumatics in a dairy operation:

• Mount the valves close to the cylinders to avoid long air lines and wasted energy.
• Mount the cylinders so they can be easily cleaned.
• Decentralize valve manifolds on larger production lines.
• Size pneumatic systems for optimal performance to avoid wasting energy on compressed air.
• Ensure the air pressure is constant to maintain optimal actuator cushioning by placing the regulators close to the actuators.
• Filter the compressed air according to the applications for which it is being used. If possible, place filters by each valve manifold.
• Lubrication for pneumatic components generally may not be needed, but if it is, be sure to use food-grade (type NSF H1) lubricants.

Pneumatics offers abundant advantages to dairy processors. Pneumatic devices can handle the rigors of a dairy’s rugged washdown environment. They’re easy to upgrade or change, giving dairy operations the flexibility to respond to changing consumer preferences. They can be used almost anywhere, tapping into compressed air that’s available throughout the plant. Finally, pneumatic technology can help dairy operations comply with regulations, protect workers and equipment from harm, and help maintain a high level of production and minimize downtime through predictive maintenance.